Touch safe fuse module with improved wiring lugs

TECHNICAL FIELD

p-0002This invention relates generally to fuses and to wiring lugs used in fuse modules. More particularly, the invention relates to an improvement of the wiring lugs used by fuse modules to provide a connection between a terminal element and an electrical lead.

BACKGROUND

p-0003Fuse modules provide a means for fuses to be incorporated into an electrical circuit. Typically, a fuse module has two terminals for electrical leads and two terminals for a fuse connection. The mechanism that has typically been used to connect electrical leads to fuse connections has been the wiring lug, which contains electrical lead terminals and fuse clip terminals. A load side electrical lead is attached to a first lead terminal. A line side electrical lead is attached to a second lead terminal. The circuit through the fuse module then may be completed by the installation of the fuse in the fuse terminal, which electrically connects the line side and load side lead terminals through the fuse element.

p-0004Previous wiring lugs have used screw terminals where the electrical leads couple to the lead terminals via the use of screws. The electrical leads are brought into contact with the screws while in a first position. The screws are then placed in a second position, creating an electrical and mechanical connection between the electrical leads and the screw by arresting the leads between the screw and a surface. These connections may be formed by placing the lead under the head of the screw and the screw head coming in contact with a surface. Alternatively, these screw terminals may involve the electrical lead being wound around the screw terminals and the screw rotating to the surface. Alternatively, the screw could press the electrical lead to the terminal by directly applying physical pressure at the base of the screw. These previous methods led to problems with heat transfer and electrical resistance. Additionally, high torque is needed to secure the electrical leads to the screw terminals, which is a problem in itself and which may damage the leads. Additional features of previous embodiments included securing devices that have congruent teeth flanking either side of the electrical lead, leading to the possibility of damaging the leads during installation.

p-0005An additional problem with conventional lugs relates to the conductive materials used in wiring lugs. Clips used in such applications have been made of conductive materials that have inherent spring properties to them, such as C19025, C7025, or C7026, to provide the necessary physical properties to secure the fuses to the wiring lugs. In addition to the expense associated with such conductive materials, there is usually an amount of ‘scrap’ conductive material that is unused. This excess material has been undesirable as these devices used special copper alloys that are expensive. The use of these copper alloys also leads to the additional problem of requiring a hydraulic press because the conductive material is too strong to be manipulated with hand tools, thereby further increasing manufacturing costs.

p-0006Therefore, a need exists in the art for a wiring lug that can securely couple to both an electrical lead and a fuse terminal while making use of minimal conductive materials and labor.

SUMMARY

p-0007The invention relates generally to a wiring lug that can connect electrical leads and fuse terminals. This connection is facilitated by an improved fastening mechanism that couples the electrical lead to the wiring lug as will be described below.

p-0008The wiring lug according to the invention comprises a fuse clip that receives a fuse contact and a pressure plate that couples to an electrical conductor. A box lug moves with respect to the pressure plate to crimp the conductor between an interior of the box lug and the pressure plate. The crimping in this fashion can provide an increased area of electrical contact between the conductor and the pressure plate. One or more projections formed in the pressure plate can increase a holding strength of the wiring lug on the conductor. The projections also can maintain alignment of the pressure plate and the box lug by mating with corresponding apertures in the box lug. This wiring lug may be used in fuse holders as described below.

p-0009According to one aspect of the invention, a wiring lug can include a fuse clip member and a box lug. The fuse clip member comprises a fuse clip for receiving a contact of a fuse and a first pressure plate for contacting an electrical conductor. The box lug includes an opening into which the pressure plate of the fuse clip member is disposed, where the interior bottom surface of the box lug comprises a second pressure plate. A securing member determines movement of the box lug with respect to the fuse clip member. When the securing member that is operably coupled to the box lug is in a first position, the first pressure plate of the fuse clip member and the second pressure plate of the box lug are disposed in a non-clamping relationship and do not claim the conductor therebetween. When the securing member is in a second position, the first pressure plate and the second pressure plate are coupled by moving the box lug from a first position to a second position, thereby securing the conductor between them.

p-0010In accordance with another aspect of the invention, the wiring lug may be incorporated into a fuse module. Two wiring lug may be installed into a fuse module where a fuse may be installed into the wiring lugs to complete an electrical circuit. The wiring lugs used in the fuse module may receive an electrical conductor from either the line side or the load side, respectively, of an electrical circuit. The electrical conductors may then be separately coupled between the first pressure plate and the second pressure plate in one of the wiring lugs. A fuse may then be installed in the fuse module providing an electrical connection between the two fuse clips of the separate wiring lugs.

p-0011In accordance with yet another aspect of the invention, the fuse clip member may be formed from a single piece of conductive material. The fuse clip member formation beings with a primary member. A piece of the primary member that is substantially rectangular and located in the center of the primary member is split away on all but one side, forming a secondary member. The distal end of the secondary member is rotated such that at least a portion of the secondary member is substantially perpendicular to the primary member. The secondary member is configured to become the pressure plate. The primary member is then bent to form a fuse clip by disposing two ends of the primary member adjacent to each other. A spring is disposed around the two ends of the primary member to bias the two ends towards each other. This method of creating a fuse clip member allows for minimal generation of waste, while creating a single member that can receive a fuse contact and can act as a pressure plate used as an electrical conductor contact.

p-0012These and other aspects, objects, and features of the invention will become apparent to those having ordinary skill in the art upon consideration of the following detailed description of exemplary embodiments exemplifying the best mode for carrying out the invention as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

For a complete understanding of the invention and the advantages thereof, reference is now made to the following description in conjunction with accompanying figures in which:

<figref idrefs="DRAWINGS">FIG. 1</figref> is a cross sectional view of a fuse module that utilizes wiring lugs according to one exemplary embodiment of the invention.

<figref idrefs="DRAWINGS">FIG. 2</figref> is a perspective view of the exemplary fuse module illustrated in <figref idrefs="DRAWINGS">FIG. 1</figref>.

<figref idrefs="DRAWINGS">FIG. 3</figref> is a partial elevation view of a wiring lug according to one exemplary embodiment of the invention.

<figref idrefs="DRAWINGS">FIG. 4A</figref> is a side elevation view of a box lug of the wiring lug illustrated in <figref idrefs="DRAWINGS">FIG. 3</figref> according to one exemplary embodiment of the invention.

<figref idrefs="DRAWINGS">FIG. 4B</figref> is a partial elevation view of the box lug illustrated in <figref idrefs="DRAWINGS">FIG. 4A</figref> according to one exemplary embodiment of the invention.

<figref idrefs="DRAWINGS">FIG. 5</figref> is a side elevation of a fuse clip member of the wiring lug according to one exemplary embodiment of the invention.

<figref idrefs="DRAWINGS">FIG. 6A</figref> is a cross sectional view of the wiring lug illustrated in <figref idrefs="DRAWINGS">FIG. 3</figref>, where the wiring lug is in a first, open position according to one exemplary embodiment of the invention.

<figref idrefs="DRAWINGS">FIG. 6B</figref> is a cross sectional view of the wiring lug illustrated in <figref idrefs="DRAWINGS">FIG. 6A</figref>, where the wiring lug is receiving an electrical lead while in the first, open position according to one exemplary embodiment of the invention.

<figref idrefs="DRAWINGS">FIG. 6C</figref> is a cross sectional view of the wiring lug illustrated in <figref idrefs="DRAWINGS">FIG. 6B</figref>, where the wiring lug has received an electrical lead and is in a second, closed position according to one exemplary embodiment of the invention.

<figref idrefs="DRAWINGS">FIG. 7A</figref> is a flowchart illustrating a method for manufacturing a fuse clip member according to one exemplary embodiment of the invention.

<figref idrefs="DRAWINGS">FIG. 7B</figref> is a front elevation view of a material blank for forming the fuse clip member of <figref idrefs="DRAWINGS">FIG. 6</figref> using the method of <figref idrefs="DRAWINGS">FIG. 7A</figref> according to one exemplary embodiment of the invention.

<figref idrefs="DRAWINGS">FIGS. 7C-7H</figref> are views of the formation of the fuse clip member from the blank illustrated in <figref idrefs="DRAWINGS">FIG. 7B</figref> according to the method depicted in <figref idrefs="DRAWINGS">FIG. 7A</figref> according to one exemplary embodiment of the invention.

p-0026The appended drawings illustrate only exemplary embodiments of the invention and therefore do not limit its scope, as the invention may admit other equally effective embodiments.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

p-0027The invention may be better understood by reading the following description of non-limitative, exemplary embodiments with reference to the attached drawings wherein like parts of each of the figures are identified by the same reference characters.

p-0028With reference to <figref idrefs="DRAWINGS">FIGS. 1 and 2</figref>, an exemplary embodiment of a wiring lug disposed in a fuse module will be described. <figref idrefs="DRAWINGS">FIG. 1</figref> is a cross sectional view of a fuse module <b>100</b> that utilizes two wiring lugs <b>102</b> (illustrated separately as wiring lugs <b>102</b><i>a </i>and <b>102</b><i>b </i>and collectively or individually referred to as wiring lugs <b>102</b>) according to one exemplary embodiment of the invention. <figref idrefs="DRAWINGS">FIG. 2</figref> is a perspective view of the exemplary fuse module <b>100</b> illustrated in <figref idrefs="DRAWINGS">FIG. 1</figref>.

p-0029Referring to <figref idrefs="DRAWINGS">FIG. 1</figref>, the fuse module <b>100</b> comprises a housing <b>101</b> in which the two wiring lugs <b>102</b><i>a</i>, <b>102</b><i>b </i>are disposed. The housing <b>101</b> is suitably formed to hold the wiring lugs <b>102</b><i>a</i>, <b>102</b><i>b </i>in position with respect to each other. Each of the wiring lugs <b>102</b> comprises a fuse clip member <b>104</b>. The fuse clip member <b>104</b> comprises a pressure plate <b>104</b><i>a </i>and a fuse clip <b>104</b><i>b</i>. The fuse clip <b>104</b><i>b </i>comprises two members biased together by a backing spring <b>106</b>.

p-0030Each of the wiring lugs <b>102</b> further comprises a box lug <b>108</b>. Each box lug <b>108</b> comprises a pressure plate <b>108</b><i>a</i>. A screw-type fastener <b>110</b> is threadably coupled to the box lug <b>108</b> for moving the box lug <b>108</b> with respect to the pressure plate <b>104</b><i>a </i>of the fuse clip member <b>104</b>. The fastener <b>110</b> is accessible via an aperture <b>111</b> in the fuse module <b>100</b>. The aperture <b>111</b> is configured to hold the fastener <b>110</b> in a substantially fixed position with regard to the fuse clip member <b>104</b>. As illustrated in <figref idrefs="DRAWINGS">FIG. 1</figref>, a diameter of the aperture <b>111</b> is smaller than a diameter of the fastener <b>110</b>, thereby holding the fastener <b>110</b> in position with respect to the fuse clip member <b>104</b>, and particularly with respect to the pressure plate <b>104</b><i>a </i>of the fuse clip member <b>104</b>.

p-0031As illustrated in <figref idrefs="DRAWINGS">FIG. 1</figref>, the fuse module <b>100</b> includes two wiring lugs <b>102</b><i>a, </i><b>102</b><i>b</i>. The box lug <b>108</b> in the first wiring lug <b>102</b><i>a </i>is in a first, open position, and the box lug <b>108</b> in the second wiring lug <b>102</b><i>b </i>is in a second, closed position. In the first, open position, the pressure plate <b>108</b><i>a </i>of the box lug <b>108</b> is spaced apart from the pressure plate <b>104</b><i>a </i>of the fuse clip member <b>104</b>. In the second, closed position, the pressure plate <b>108</b><i>a </i>of the box lug <b>108</b> is disposed adjacent to the pressure plate <b>104</b><i>a </i>of the fuse clip member <b>104</b> such that a conductor (not shown) can be crimped between the pressure plates <b>104</b><i>a</i>, <b>108</b><i>a. </i>

p-0032In the exemplary embodiment illustrated in <figref idrefs="DRAWINGS">FIG. 1</figref>, electrical leads (not shown) can be coupled to the fuse module <b>100</b> though lead apertures <b>118</b><i>a</i>, <b>118</b><i>b </i>at either side of the fuse module <b>100</b>. The lead aperture <b>118</b><i>a </i>receives a line side electrical lead for the wiring lug <b>102</b><i>a. </i>The line side electrical lead can be crimped between the pressure plates <b>104</b><i>a</i>, <b>108</b><i>a </i>of the wiring lug <b>102</b><i>a</i>. The lead aperture <b>118</b><i>b </i>receives a load side electrical lead for the wiring lug <b>102</b><i>b. </i>The load side electrical lead can be crimped between the pressure plates <b>104</b><i>a</i>, <b>108</b><i>a </i>of the wiring lug <b>102</b><i>b. </i>

p-0033For each wiring lug <b>102</b>, the box lug <b>108</b> is moved from the first, open position to the second, closed position by turning the fastener <b>110</b>. The fastener <b>110</b> mates with the box lug <b>108</b> such that turning the fastener <b>110</b> causes the box lug <b>108</b> to move up or down on the fastener <b>110</b>. Since the fastener <b>110</b> and the pressure plate <b>104</b><i>a </i>of the fuse clip member <b>104</b> are substantially maintained in a fixed position with regard to each other, movement of the box lug <b>108</b> along the fastener <b>110</b> moves the box lug <b>108</b> with respect to the pressure plate <b>104</b><i>a </i>of the fuse clip member <b>104</b>. Accordingly, the box lug <b>108</b> can move from the open position (illustrated with wiring lug <b>102</b><i>a </i>in <figref idrefs="DRAWINGS">FIG. 1</figref>) to the closed position (illustrated with wiring lug <b>102</b><i>b </i>in <figref idrefs="DRAWINGS">FIG. 1</figref>).

p-0034The fuse module <b>100</b> illustrated in <figref idrefs="DRAWINGS">FIG. 1</figref> further includes a fuse receptacle <b>120</b> for receiving a fuse (not shown). The fuse engages the fuse clips <b>104</b><i>b </i>of the wiring lugs <b>102</b><i>a, </i><b>102</b><i>b </i>to connect the two wiring lugs <b>102</b><i>a</i>, <b>102</b><i>b</i>, thereby completing the connection between the line side and load side electrical leads. In the illustrated, exemplary embodiment, the fuse receptacle <b>120</b> is disposed in a top portion <b>112</b> of the fuse module <b>100</b>. A bottom portion <b>114</b> of the fuse module <b>100</b> includes structures to attach the fuse module <b>100</b> to other surfaces, such as an electrical box. For example, a DIN spring <b>116</b> provides a securing mechanism for the fuse module <b>100</b> to apply pressure to a DIN rail. Any suitable means for securing the fuse module <b>100</b> to a surface may be used, such as screws, clips, or other suitable devices.

p-0035<figref idrefs="DRAWINGS">FIG. 3</figref> is a partial elevation view of the wiring lug <b>102</b> according to one exemplary embodiment of the invention. Referring to <figref idrefs="DRAWINGS">FIG. 3</figref>, the wiring lug <b>102</b> is in the closed position where the pressure plate <b>108</b><i>a </i>of the box lug <b>108</b> is disposed adjacent to the pressure plate <b>104</b><i>a </i>of the fuse clip member <b>104</b>.

p-0036In this exemplary embodiment, the pressure plate <b>104</b><i>a </i>of the fuse clip member <b>104</b> comprises a projection <b>302</b> extending toward the pressure plate <b>108</b><i>b </i>of the box lug <b>108</b>. As illustrated, the projection <b>302</b> comprises a v-shape. However, a semi-circular, square, or other suitable shape of the projection <b>302</b> is within the scope of the invention. Although not illustrated in <figref idrefs="DRAWINGS">FIG. 3</figref>, the pressure plate <b>104</b><i>a </i>of the fuse clip member <b>104</b> can comprise a similar projection on a side of the pressure plate <b>108</b><i>b </i>opposite the projection <b>302</b>. In this embodiment, the projections in the pressure plate <b>104</b><i>a </i>create two “teeth” extending toward the pressure plate <b>108</b><i>a </i>of the box lug <b>108</b>.

p-0037The box lug <b>108</b> further comprises an aperture <b>304</b> disposed in a position corresponding to the projection <b>302</b> of the pressure plate <b>104</b><i>a </i>of the fuse clip member <b>104</b>. As illustrated, the aperture <b>304</b> is disposed in a side wall <b>306</b> of the box lug <b>108</b>. The aperture <b>304</b> also is disposed in the pressure plate <b>108</b><i>a </i>of the box lug <b>108</b>. While illustrated as semi-circular in shape, a v-shape, square, or other suitable shape of the aperture <b>304</b> is within the scope of the invention. Accordingly, the projection <b>302</b> of the fuse clip member <b>104</b> is visible and extends through the aperture <b>304</b> of the box lug <b>108</b>. In an exemplary embodiment, the box lug <b>108</b> can comprise a second aperture on an opposite side of the pox lug <b>108</b> for receiving the second projection discussed previously.

p-0038In the exemplary embodiment illustrated in <figref idrefs="DRAWINGS">FIG. 3</figref>, the projection <b>302</b> provides additional strength to hold a conductor (not shown) that is crimped between the pressure plates <b>104</b><i>a</i>, <b>108</b><i>a</i>. The projection <b>302</b> can help maintain the position of the box lug <b>108</b> with respect to the fuse clip member <b>104</b>. The projection <b>302</b> and the aperture <b>304</b> together from a pinch point within which the conductor can be secured. The pinch point secures the conductor with less torque exerted by the fastener <b>110</b>.

p-0039In an alternative exemplary embodiment, the projection <b>302</b> can be a continuous projection extending across the pressure plate <b>104</b><i>a </i>of the fuse clip member <b>104</b>. In this embodiment, a conductor may deform around the projection <b>302</b> when crimped between the pressure plates <b>104</b><i>a</i>, <b>108</b><i>a</i>, thereby providing additional holding strength to retain the conductor within the wiring lug <b>102</b>.

p-0040<figref idrefs="DRAWINGS">FIG. 3</figref> also illustrates the backing spring <b>106</b> attached to the fuse clip <b>104</b><i>b </i>of the fuse clip member <b>104</b>. The backing spring <b>106</b> has a spring force that biases the two sides of the fuse clip <b>104</b><i>b </i>together. Such bias aids in securing a fuse terminal of a fuse to the fuse clip <b>104</b><i>b </i>when the fuse is installed in the fuse module <b>100</b> (<figref idrefs="DRAWINGS">FIG. 1</figref>).

p-0041The exemplary embodiment in <figref idrefs="DRAWINGS">FIG. 3</figref> further illustrates a notch <b>308</b> in the pressure plate <b>104</b><i>a </i>of the fuse clip member <b>104</b>. The notch <b>308</b> defines a transition from a first portion of the pressure plate <b>104</b><i>a </i>to a second portion of the pressure plate <b>104</b><i>a</i>. The first portion of the pressure plate <b>104</b><i>a </i>is wider than the interior dimension of the box lug <b>108</b>. Accordingly, the pressure plate <b>104</b><i>a </i>of the fuse clip member <b>104</b> cannot be inserted into the box lug <b>108</b> past the notch <b>308</b>. The second portion of the pressure plate <b>104</b><i>a </i>is narrower than the interior dimension of the box lug <b>108</b> to allow that portion of the pressure plate <b>104</b><i>a </i>to be inserted into the box lug <b>108</b>.

p-0042With reference to <figref idrefs="DRAWINGS">FIGS. 4A and 4B</figref>, features of the box lug <b>108</b> will be described. <figref idrefs="DRAWINGS">FIG. 4A</figref> is a side elevation view of the box lug <b>108</b> of the wiring lug <b>102</b> illustrated in <figref idrefs="DRAWINGS">FIG. 3</figref> according to one exemplary embodiment of the invention. <figref idrefs="DRAWINGS">FIG. 4B</figref> is a partial elevation view of the box lug <b>108</b> illustrated in <figref idrefs="DRAWINGS">FIG. 4A</figref> according to one exemplary embodiment of the invention. As depicted, a first aperture <b>304</b><i>a </i>is disposed on a first side wall <b>306</b><i>a </i>of the box lug <b>108</b>. A corresponding aperture <b>304</b><i>b </i>is disposed on an opposite side wall <b>306</b><i>b </i>of the box lug <b>108</b>. The apertures <b>304</b><i>a</i>, <b>304</b><i>b </i>also extend partially into the pressure plate <b>108</b><i>a</i>, which comprises the inner, lower surface of the box lug <b>108</b>. The two apertures <b>304</b><i>a, </i><b>304</b><i>b </i>are disposed to accommodate two projections <b>302</b> (<figref idrefs="DRAWINGS">FIG. 3</figref>) on the pressure plate <b>104</b><i>a </i>of the fuse clip member <b>104</b>. When an electrical lead is placed between either of the two projections <b>306</b><i>a</i>-<i>b </i>and the corresponding apertures <b>304</b><i>a</i>, <b>304</b><i>b</i>, the securing pressure on the electrical lead is increased.

p-0043A front area and back area of the box lug <b>108</b> are open, allowing access to an interior of the box lug <b>108</b>. These openings allow the fuse clip member <b>104</b> to be inserted and allow the box lug <b>108</b> to move up or down relative to the fuse clip member <b>104</b>. In an alternative exemplary embodiment (not shown), the front area and back area can have partial walls that restrict the movement of the fuse clip member <b>104</b> with respect to the box lug <b>108</b>.

p-0044<figref idrefs="DRAWINGS">FIG. 4B</figref> also depicts a fastener aperture <b>402</b> in a top surface of the box lug <b>108</b>. The fastener aperture <b>402</b> comprises threads (or simply a suitable thickness that acts as a thread) to threadably engage corresponding threads on the fastener <b>110</b> (<figref idrefs="DRAWINGS">FIG. 1</figref>).

p-0045Although the pressure plate <b>108</b><i>a </i>is depicted in <figref idrefs="DRAWINGS">FIG. 4B</figref> as a continuous member, the apertures <b>304</b><i>a</i>, <b>304</b><i>b </i>can be connected across the pressure plate <b>108</b><i>a </i>such that the pressure plate <b>108</b><i>a </i>includes a gap extending from side wall <b>306</b><i>a </i>to side wall <b>306</b><i>b</i>. In this embodiment, the projection <b>302</b> of the pressure plate <b>104</b><i>a </i>of the fuse clip member <b>104</b> can extend into the gap when the pressure plate <b>108</b><i>a </i>of the box lug <b>108</b> is moved to the closed position, thereby providing increased holding strength for a conductor crimped between the pressure plates <b>104</b><i>a</i>, <b>108</b><i>a. </i>

p-0046<figref idrefs="DRAWINGS">FIG. 5</figref> is a side elevation of the fuse clip member <b>104</b> according to one exemplary embodiment of the invention. The two major sections of the fuse clip member <b>104</b> are the pressure plate <b>104</b><i>a </i>and the fuse clip <b>104</b><i>b</i>. The fuse clip <b>104</b><i>b </i>comprises a first portion <b>502</b> and a second portion <b>504</b> of a continuous member. The second portion <b>504</b> is bent toward the first portion <b>502</b> to form the fuse clip <b>104</b><i>b</i>. The pressure plate extends substantially perpendicularly to the first portion <b>502</b> of the fuse clip <b>104</b><i>b</i>. The pressure plate <b>104</b><i>a </i>comprises the projection <b>302</b> and can secure an electrical lead (not shown) between the fuse clip member <b>104</b> and the box lug <b>108</b> (<figref idrefs="DRAWINGS">FIG. 3</figref>).

p-0047The operation of a wiring lug being operated from the open position to the closed position will now be described with reference to <figref idrefs="DRAWINGS">FIGS. 6A-6C</figref>. <figref idrefs="DRAWINGS">FIG. 6A</figref> is a cross sectional view of the wiring lug <b>102</b> depicted in <figref idrefs="DRAWINGS">FIG. 3</figref>, where the wiring lug <b>102</b> is in the first, open position according to one exemplary embodiment of the invention. The wiring lug <b>102</b> comprises the box lug <b>108</b> operably coupled to the fuse clip member <b>104</b> such that one or both of those components may move with respect to each other. When in the first position, the box lug <b>108</b> may be moved up or down with respect to the fuse clip member <b>104</b>.

p-0048<figref idrefs="DRAWINGS">FIG. 6B</figref> is a cross sectional view of the wiring lug <b>102</b> illustrated in <figref idrefs="DRAWINGS">FIG. 6A</figref>, where the wiring lug <b>102</b> is receiving an electrical lead <b>802</b> while the wiring lug <b>102</b> is in the first, open position according to one exemplary embodiment of the invention. <figref idrefs="DRAWINGS">FIG. 6C</figref> is a cross sectional view of the wiring lug <b>102</b> illustrated in <figref idrefs="DRAWINGS">FIG. 6A</figref>, where the wiring lug <b>102</b> has received an electrical lead <b>802</b>, such as a conductor, and is in the second, closed position according to one exemplary embodiment of the invention. In <figref idrefs="DRAWINGS">FIG. 6C</figref>, the fastener <b>110</b> has been rotated to move the box lug <b>108</b> with respect to the fuse clip member <b>104</b>, such that the electrical lead <b>802</b> is crimped between the pressure plate <b>104</b><i>a </i>of the fuse clip member <b>104</b> and the pressure plate <b>108</b><i>a </i>of the box lug <b>108</b>.

p-0049In the exemplary embodiment previously described, the rotation of the fastener <b>110</b> from a first position to a second position causes the pressure plate <b>108</b><i>a </i>from the box lug <b>108</b> to move closer to the pressure plate <b>104</b><i>a</i>, which is in a fixed position. In an alternative exemplary embodiment (not shown), the rotation of the fastener <b>110</b> from a first position to a second position may cause the pressure plate <b>104</b><i>a </i>to move toward the pressure plate <b>108</b><i>a </i>of the box lug <b>108</b>, which can be in a fixed position.

p-0050As previously discussed, the fuse clip member <b>104</b> comprises at least one projection <b>302</b>. Each projection can correspond to an aperture <b>304</b> in the box lug <b>108</b>. In an exemplary embodiment, the projection <b>302</b> may be smaller than the aperture <b>304</b> in the base of the box lug <b>108</b>. This projection <b>302</b> and aperture <b>304</b> may act to further restrict the movement of the electrical lead <b>802</b> installed in the wiring lug <b>102</b> by introducing a roughness that aids in restricting the electrical lead <b>802</b> in the wiring lug <b>102</b>. The projections <b>302</b> can allow for a more secure connection of the electrical lead <b>802</b> to the wiring lug <b>102</b> with lower torque applied to the screw fastener <b>110</b> to secure the electrical lead <b>802</b>.

p-0051By use of the pressure plates <b>104</b><i>a</i>, <b>108</b><i>a</i>, the electrical lead <b>802</b> is in contact with the fuse clip member <b>104</b> for substantially the length of the pressure plate <b>104</b><i>a </i>where the electrical lead <b>802</b> is in contact with the pressure plate <b>104</b><i>a</i>. This contact allows more of the electrical lead <b>802</b> to be in contact with the terminal and removes the single physical point of contact between the electrical lead <b>802</b> and the pressure plate <b>104</b><i>a</i>. The pressure plate <b>104</b><i>a </i>acts as the entire contact surface. In addition, with more surface area in contact, the electrical connection is more secure. Furthermore, the distribution of the contact between the electrical lead <b>802</b> and the pressure plate <b>104</b><i>a </i>reduces generated heat.

p-0052With reference to <figref idrefs="DRAWINGS">FIGS. 7A-7H</figref>, an exemplary method for manufacturing the fuse clip member <b>104</b> from a single piece of conductive material will be described. <figref idrefs="DRAWINGS">FIG. 7A</figref> is a flowchart illustrating a method <b>700</b> for manufacturing the fuse clip member <b>104</b> according to one exemplary embodiment.

p-0053The method <b>700</b> includes providing a primary member of electrically conductive material as shown in step <b>780</b>. The primary member then has a secondary member formed therein as shown at step <b>785</b>. The secondary member is then molded to receive an electrical contact at step <b>790</b>, and the primary member is molded to receive the fuse contact at step <b>795</b>. The method <b>700</b> described in <figref idrefs="DRAWINGS">FIG. 7A</figref> is illustrated in <figref idrefs="DRAWINGS">FIGS. 7B-7H</figref> and described in the following paragraphs.

p-0054<figref idrefs="DRAWINGS">FIG. 7B</figref> is a front elevation view of the fuse clip member <b>104</b> from <figref idrefs="DRAWINGS">FIG. 6</figref> in its unprocessed state, where the fuse clip member <b>104</b> comprises only a primary member <b>701</b> of conductive material according to one exemplary embodiment of the invention. In an exemplary embodiment, the fuse clip member <b>104</b> may be made entirely from a single piece of conductive material that has a substantially rectangular shape. The conductive material used in the exemplary embodiment may C110 copper or any other suitable conductive material. An advantage of C110 copper is that it does not require the use of a hydraulic press to bend it into the desired shape. Bending may be accomplished by a person using simple hand tools if needed. An additional advantage of the method <b>700</b> is that is allows the use of conductive materials that do not need to have inherent spring properties as the method of manufacture creates the spring properties used in the invention.

p-0055<figref idrefs="DRAWINGS">FIG. 7C</figref> is a front elevation view of the primary member <b>701</b> from <figref idrefs="DRAWINGS">FIG. 7B</figref>, where a rectangular projection is made from the primary member <b>701</b>, creating a secondary member <b>702</b>. The secondary member <b>702</b> has three sides physically separated from the primary member <b>701</b> and one side still coupled to the primary member <b>701</b> at the secondary member proximal end <b>704</b>. The width of the secondary member <b>702</b> is a first predetermined distance <b>712</b><i>a</i>, <b>712</b><i>b </i>from the sides of the primary member <b>701</b>. The length of the secondary member <b>702</b> is defined by the secondary member proximal end <b>704</b> and secondary member distal end <b>706</b>. The secondary member proximal end <b>704</b> starts at a second predetermined distance <b>714</b> from the primary member proximal end <b>708</b>. The secondary member distal end <b>706</b> is formed at a third predetermined distance <b>716</b> from the primary member distal end <b>710</b>. The secondary member <b>702</b> may be defined by decoupling the secondary member distal end <b>706</b> from the primary member <b>701</b>. Decoupling maybe accomplished by any means known to those having ordinary skill in the art, including cutting or stamping. Such (decoupling would allow all but the secondary member proximal end <b>704</b> to move relative to the primary member. The secondary member <b>702</b> remains coupled to the primary member <b>701</b> at the secondary member proximal end <b>704</b>.

p-0056<figref idrefs="DRAWINGS">FIG. 7D</figref> is a partial elevation view of the primary member <b>701</b> and the secondary member <b>702</b> from <figref idrefs="DRAWINGS">FIG. 7C</figref>, where the secondary member distal end <b>706</b> has been separated from the primary member <b>701</b> according to one exemplary embodiment of the invention. <figref idrefs="DRAWINGS">FIG. 7E</figref> is a side elevation view of the primary member <b>701</b> and the secondary member <b>702</b> from <figref idrefs="DRAWINGS">FIG. 7C</figref>, where the secondary member distal end <b>706</b> has been separated from the primary member <b>701</b> according to one exemplary embodiment of the invention.

p-0057<figref idrefs="DRAWINGS">FIG. 7F</figref> is a side elevation view of the primary member <b>701</b> and the secondary member <b>702</b> from <figref idrefs="DRAWINGS">FIG. 7E</figref>, where the secondary member <b>702</b> has been extended away from the primary member <b>701</b> to become substantially perpendicular to the primary member <b>701</b>, forming the pressure plate <b>104</b><i>a </i>according to one exemplary embodiment of the invention. According to an exemplary embodiment, an additional deformation in the pressure plate <b>104</b><i>a </i>may be made by forming the projection <b>302</b> in the pressure plate <b>104</b><i>a</i>. The location of the projection <b>302</b> may correspond to the projection aperture <b>304</b> in the box lug <b>108</b>. A single projection <b>302</b> or multiple projections can be made. A single projection <b>302</b> can be formed on an edge of the pressure plate <b>104</b><i>a </i>or can be continuous across the pressure plate <b>104</b><i>a. </i>

p-0058<figref idrefs="DRAWINGS">FIG. 7G</figref> is a side elevation view of the primary member <b>701</b> and the secondary member <b>702</b> from <figref idrefs="DRAWINGS">FIG. 7F</figref>, where the primary member distal end <b>710</b> has been bent away from the pressure plate <b>104</b><i>a </i>to be substantially proximate to the primary member proximal end <b>708</b> according to one exemplary embodiment of the invention. <figref idrefs="DRAWINGS">FIG. 7H</figref> is a side elevation view of the primary member <b>701</b> and the secondary member <b>702</b> from <figref idrefs="DRAWINGS">FIG. 7G</figref>, where the primary member distal end <b>710</b> and the primary member proximal end <b>708</b> are coupled by a backing spring <b>106</b>, thereby creating a fuse clip <b>104</b><i>b </i>according to one exemplary embodiment of the invention.

p-0059Any spatial references herein, such as, for example, “upper,” “lower,” “above,” “below,” “rear,” “between,” “vertical,” “angular,” “beneath,” “top,” “bottom,” “side,” etc., are for the purpose of illustration only and do not limit the specific orientation or location of the described structure.

p-0060Therefore, the invention is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the invention may be modified and practiced in different but equivalent manners apparent to those having ordinary skill in the art and having the benefit of the teachings herein. While numerous changes may be made by those having ordinary skill in the art, such changes are encompassed within the spirit and scope of this invention as defined by the appended claims. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the invention as defined by the claims below. The terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee.